We report in situ, simultaneous measurements of both drag and normal forces in magnetorheological finishing (MRF) for what is believed to be the first time, using a spot taking machine (STM) as a test bed to take MRF spots on stationary parts. The measurements are carried out over the entire area where material is being removed, i.e., the projected area of the MRF removal function/spot on the part surface, using a dual force sensor. This approach experimentally addresses the mechanisms governing material removal in MRF for optical glasses in terms of the hydrodynamic pressure and shear stress, applied by the hydrodynamic flow of magnetorheological fluid at the gap between the part surface and the STM wheel. This work demonstrates that the volumetric removal rate shows a positive linear dependence on shear stress. Shear stress exhibits a positive linear dependence on a material figure of merit that depends upon Young's modulus, fracture toughness, and hardness. A modified Preston's equation is proposed that better estimates MRF material removal rate for optical glasses by incorporating mechanical properties, shear stress, and velocity.

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We report on magnetorheological finishing (MRF) spotting experiments performed on glasses and ceramics using a zirconia-coated carbonyl-iron (CI)-particle-based magnetorheological (MR) fluid. The zirconia-coated magnetic CI particles were prepared via sol-gel synthesis in kilogram quantities. The coating layer was approximately 50-100 nm thick, faceted in surface structure, and well adhered. Coated particles showed long-term stability against aqueous corrosion. "Free" nanocrystalline zirconia polishing abrasives were cogenerated in the coating process, resulting in an abrasive-charged powder for MRF. A viable MR fluid was prepared simply by adding water. Spot polishing tests were performed on a variety of optical glasses and ceramics over a period of nearly three weeks with no signs of MR fluid degradation or corrosion. Stable material removal rates and smooth surfaces inside spots were obtained.